HANGCHA XF Series, Operational And Maintenance Manual

Page 1: ...XF series OPERATION MANUAL 1 0t X5 5T XF series Internal Combustion Counterbalanced Forklift Truck Operational and Maintenance Manual Original Instruction HANGCHA GROUP CO LTD 04 2018...

Page 2: ...river maintenance personnel and equipment manager must read and comprehend this manual before use Because of the update and improvements of our products there may be some differences between this oper...

Page 3: ...vel 45 3 Pick up 46 4 Stacking load 46 5 Remove load 47 VII Parking 48 1 Parking daily 48 2 Park the truck for a long time 48 3 Running after storing for a long time 49 VIII Maintenance 50 1 Preventiv...

Page 4: ...perational method of lead acid battery 125 XVI Use installation and safety rules of attachment 129 XVII Description of OPS System 131 XVIII Relevant safety command and standard 133 XVI Maintenance rec...

Page 5: ...r a long time 18 If the truck suddenly gets out of order or for leakage of electrolyte hydraulic oil or brake oil when lifting goods or grade climbing leave truck in safe state and contact service tec...

Page 6: ...cation or alteration to a powered industrial truck manufacturer and the user shall 1 Arrange for the modification or alteration to be designed tested and implemented by an engineer s expert in industr...

Page 7: ...f main parts or component 1 Fork 2 Load backrest 3 Tilt cylinder 4 Mast 5 Lift cylinder 6 Steering wheel 7 Overhead guard 8 Seat 9 Cover hood 10 Counterbalance weight 11 Rear wheel 12 Truck frame 13 F...

Page 8: ...r seperator Indicator light K Engine oil pressure warning light L Charging indicator light M Left turning indicator N Right turning indicator 1 0t 3 5t W43 forklift instrument LCD A Water temperature...

Page 9: ...C Timer E Neutral position start up indicator G Transmission oil temperature warning light H Parking indicator I Preheat indicator light K Engine oil pressure warning light L Charging indicator light...

Page 10: ...ormal status LED Displayed in the range of 40 110 Caution If LCD display in the red zone please stop the truck at once Decrease the engine speed to make the engine cool Check the cooling fluid if enou...

Page 11: ...ormal rang 60 120 C the indicator light on Caution If the pointer enters the red range stop the operation instantly and slow down engine speed to cool the coolant and wait until the pointer goes into...

Page 12: ...up When the truck turns right the indicator is set backward the lamp lights up Air filter indicator O When the light is on it indicates the air inlet system is blocked stop the truck and clean the ai...

Page 13: ...ombination switch 4 Key switch 5 Lift control lever 6 Tilt control lever 7 Cup holder 8 Instrument 9 Rocker switch 10 Accelerator pedal 11 Brake pedal 12 Inching pedal 13 Brake fluid tank cap 14 Emerg...

Page 14: ...passenger cars It must be returned to the neutral position manually Turn on the headlamp and small lamp turn this switch and aim the position line on the switch knob to the relevant marking on the sw...

Page 15: ...tilt lever is pushed forward Side shift control lever Used for left shifting and right shifting of the side shift bracket Push forward move to the left Pull backward move to the right Side shifting sp...

Page 16: ...rgency disconnect switch disconnect electrical appliance with battery Re start the truck pull up the switch After shut down turn off the switch in 30 seconds Parking brake lever 15 Pull lever backward...

Page 17: ...1 and then move to R2 through R1 Caution Only place the lever in neutral can you start the engine Engine malfunction detect switch Only for CUMMINS engine 2 0t 3 5t W43 4 0t X5 5t W58 Fn Engine detect...

Page 18: ...turning the knob to inside it will be lowered Warning Turn off the key before adjusting the seat It s prohibited to adjust the position of the seat only when the truck stops In case of accident no sea...

Page 19: ...eets the safety standard Lock components To avoid opening the hood at discretion the truck is equipped with lock Use the key to open the hood Hood The hood can be swung up fully to provide easy mainte...

Page 20: ...f swallowed seek medical advice immediately Keep antifreeze away from children Fork stopper Use it to adjust fork spacing Pull up fork stopper turn 180 adjust fork spacing depending on the load to han...

Page 21: ...e a fuel leak or lead to a fire hazard 3 Before starting the engine make sure no fuel has spilled on or around the truck 4 NEVER use light flame to check the fuel level Cab rear window When ventilatin...

Page 22: ...place and install 5 Rotate the turn light according to the arrowhead in the back of lamp holder in opposite direction Take out the light change a new one and install 6 Close the lamp housing screw the...

Page 23: ...ing on the truck Never fill the fuel tank while the engine is running 5 Warm water temperature to 70 C before operation If the temperature of the water is above 70 C DO NOT open the tank cap 6 When us...

Page 24: ...he work surface should be solid and level such as a cement road asphalt or concrete road surface For truck operation the following climatic conditions apply average ambient temperature for continuous...

Page 25: ...hift mechanism if equipped when the forks are raised and loaded since this will cause the truck to become unbalanced A truck with attachments should be considered the same as a loaded truck 26 Travel...

Page 26: ...d guard which may cause loss of life DO NOT place hands into the interspace of inner mast and outer mast WARNING 34 When driver s ear noise is bigger than 80dB please adopt hearing protective measures...

Page 27: ...to tilt the mast with the load raised high 42 DO NOT tow a truck that has engine problems or whose steering system doesn t work properly or if its braking system has been disabled Obey all traffic rul...

Page 28: ...when the engine is cool Remove the dipstick clean the rod and reinstall Pull it out again and check the oil level The level should be within the marks on the dipstick 5 Check engine coolant Inspect t...

Page 29: ...30 means its value of mark can be applied for 3t 3 5t truck When the mast is in the lowest place For 1t 1 8t the truck with standard mast demands filling the hydraulic oil above the mark of 39 the tr...

Page 30: ...s lighting when the key is at ON position 8 Turn signal check Make sure that the turn signal operates properly by moving the turn signal lever 9 Hand brake check Drive truck slowly Pull hand brake lev...

Page 31: ...he forklift truck needs tires that have a high inflation pressure to carry heavy loads even a small bending of rims or damage at the tread surface could cause an accident When using an air compressor...

Page 32: ...maintain and replace element filter in time according to the requirement will lead to the damage of engine in advance With air filter Service indicator models scale mark Engine intake resistance Indic...

Page 33: ...ce mm K21 K25 11 13 4TNE92 4TNE98 New 8 12 5min old 10 14 5min 4TNV94L New 5 8 5min old 7 10 5min C240PKJ 30 8 12 S4S 12 Use finger to press the belt at the midway point between the water pump pulley...

Page 34: ...jury 3 Hydraulic transmission fluid level Open the inspections cover and pull out the oil scale Inspect if the fluid level is within the mark of the gauge 4 Mast and forks Check the mast and forks to...

Page 35: ...l hand brake Avoid injury to hand or body and avoid falling off from high place Keep safe 7 Chain Lubrication Take one brush with engine oil paint both sides on chain 8 Lubrication grease to below par...

Page 36: ...clearance Height mm Free clearance mm Brake pedal 135 5 1 3 Inching pedal 135 5 touching bolt of inching pedal brake pedal 0 mm 2 0t 3 5t Height and the free clearance Height mm Free clearance mm Brak...

Page 37: ...33 13 Cylinder bracket check only for LPG truck Pull the cylinder check if the bracket is firm restore the normal position and check if stable...

Page 38: ...uck on level ground 2 Apply lubricate to front and rear of pin roll of tilt cylinder Clean the area and remove used oil 3 Check the gear oil of drive axle housing Change the oil after 200 hours if ope...

Page 39: ...Press the priming pump until fuel comes through the bleed plug without any bubbles Fasten the bleed plug 7 Oil water separator draining Diesel Except Cummins Diesel Position an approved container und...

Page 40: ...n Blue Abnormal oil burns White Abnormal water in combustion chamber Warning Don t start the lift truck in bad ventilation space There is carbon monoxide in the exhaust gas it is very dangerous 9 Chec...

Page 41: ...cked device 3 Hydraulic oil change Park the truck on level ground lay down the forks on the floor incline the mast back and apply parking brake Put transmission in neutral position shut off the engine...

Page 42: ...ilters per one month and replace every six months Remove out the fuel filter Remove transducer Before installing new one install transducer existing put a little fuel on the filter airproof Caution Be...

Page 43: ...d to prevent rust and frost bite See Table for the oil used in the truck 2 Front wheel bearing change lubricating grease Refer to steering axle content in Maintenance Manual remove hub bearing and the...

Page 44: ...t fully backward and place a wooden block under each side of outer mast Tilt mast forward until front wheels are raised from surface Caution Do not loose nuts before the front wheels leave the ground...

Page 45: ...dditional wooden blocks under both sides of the front truck frame as shown below Take out the wheel nut of rear wheel and then replace the wheel Warning a When removing tire from wheel rim do not remo...

Page 46: ...s If the radiator fins are clogged it will lead to overheating Use compressed air vapor or water to clear Caution Clean the radiator fins by using compressed air or vapor place the muzzle to radiator...

Page 47: ...ruck because the speed of overturn is much fast than you You should hold the steering wheel handle and this practice will let you in the seats Please tie safety belt Caution Gravity and stability Fork...

Page 48: ...d capability chart This chart shows the relationship of MAX LOAD and the location of LOAD CENTER DISTANCE Check whether the load and load center distance is in the range referred by the chart Put the...

Page 49: ...ay and cold crank the engine by turning the ignition key to START Release key when engine starts Caution When the heat engine starts do not step the accelerator pedal to the end cause it may cause sta...

Page 50: ...ut down the engine For diesel trucks pull out the engine stop button Remove the key and take it with you Caution Be careful to get off Never jump off the truck Do not park the truck on travelling rout...

Page 51: ...of the loads Tilt the mast forward until forks become horizontal Elevate forks up to the position of the pallet or skid Make sure forks are positioned properly for the pallet Move forward slowly to i...

Page 52: ...ill it with oil In cold weather it is not necessary to drain the antifreeze but the water should be completely drained from the radiator 2 Park the truck for a long time When parking the truck for a l...

Page 53: ...add with new gear oil Clean the hydraulic oil reservoir and fuel reservoir removing any dirt or water and add with new hydraulic oil fuel Check the clearance of the valve gas valve cap and other parts...

Page 54: ...olyte liquid according to local environmental protection laws and regulations Follow the maintenance schedule After performing maintenance keep a record Only use Hangcha parts 1 Preventive maintenance...

Page 55: ...e Pressure gauge Sparking plug Gasoline engine Check distributor point cover and rotor Gasoline engine 1 Distributor inner IC ignition system 1 LPG Engine 1 Piping or pipe connector portion for gas le...

Page 56: ...if oil leakage at pipeline pump or oil tank Replace fuel filter First time Check nozzle and adjust the pressure diesel engine 2 Injection test Ignition timing Gasoline engine Injection moment Diesel...

Page 57: ...ck oil quantity and change oil First time 200h Inching pedal idle stroke and run condition Control valve and hydraulic clutch performance Inching valve performance Shift lever operation and loosen con...

Page 58: ...g system periodical maintenance schedule Check item Service required Tools Daily 8 hrs Monthly 166hrs 3months 500hrs Semi annual 1000hrs Annual 2000hrs Steering wheel Check clearance Check axial loose...

Page 59: ...formance If connection loosen Pipeline Damage leakage fracture Connection clamp part looseness condition Brake master cylinder brake cylinder Leakage condition Check oil level change oil Master cylind...

Page 60: ...inate foreign body Control valve rod If connection loosens Operation condition Filter Check oil leakage Multi way valve Oil leak Relief valve and tilt latching valve operation condition Measure relief...

Page 61: ...nnual 2000hrs Chain chain wheel Check chain tensity if transform damage or rust Add oil to the chain Riveting pin and looseness Chain deformation and damage If chain bearing loosen Attachm ent Check i...

Page 62: ...upporting bolts loosen Test hammer first time If lifting cylinder bottom bolt piston head bolt U type bolt and walking beam guide bolt loosen Test hammer first time Roller roller shaft and its welded...

Page 63: ...12 36 45 45 55 58 78 78 104 14 55 70 70 90 93 124 124 165 16 90 110 110 140 145 193 193 257 18 120 150 150 190 199 264 264 354 20 170 210 210 270 282 376 376 502 22 230 290 290 350 384 512 512 683 24...

Page 64: ...arts Replace them when their service life has expired sooner if they damaged Name of key safe part service life years Brake hose or hard tube l 2 Hydraulic rubber hose for lifting system l 2 Lifting c...

Page 65: ...10W 30 arctic alpine Caltex API SAE 5W 30 or refer to engine manual 3 5 4 K21 K25 Hydraulic oil L HM32 arctic alpine L HV32 36 41 1 0t 1 8t 45 51 2 0t 2 5t 49 55 3 0t 3 5t Hydrodynamic Power Transmis...

Page 66: ...liquid Radiator 35 motor antifreeze liquid add when leaving factory or FD 2 antifreeze 10 11 1t 3 5t Industrial vaseline 2 Battery terminal Lubrication grease each lubricating point 3 Automobile gene...

Page 67: ...equivalent 10 Brake liquid Brake oil box DOT3 brake liquid or equivalent 1 Antirust antifreeze solution water tank 35 motor vehicle antifreeze fluid add after leaving factory or FD 2 antifreeze 20L W...

Page 68: ...1997CD grade and above CD grade 2 Fill oil to diesel engine before leaving factory CD grade SAE 15W 40 Recommendatory gasoline engine oil viscosity under different temperature Note 1 The capability an...

Page 69: ...nd maintenance at specified locations 2 Before removing the pipe connector and related parts please use the specified container for the used liquid include antifreeze liquid engine oil hydraulic oil h...

Page 70: ...66 IX Labels Stick various nameplate and mark at different position of the truck Take 1 3 5t truck for example and 4 x5 5t truck is similar warning Rear Tire Pressure Front...

Page 71: ...rd Right flank kneading board Faste Seatblet Truck can TIP OVER Risk of serious INHURY or DEATH WARNING Do Not Jump Hold on Tight Lean Away From Impact Brace Feet 1 Danger label 2 Hang label 3 Tonnage...

Page 72: ...n and method of truck lifting Avoid the cord touch and damage the light when hoisting 3 Tonnage label For example 30 means the rated capacity is 3ton but if lift highly or with attachment then the cap...

Page 73: ...perated by anyone who is not authorized and properly trained Read the Operators Manual and all warnings carefully and make yourself familiar with your lift truck Inspect and check your lift truck dail...

Page 74: ...fe If the body is crushed between the mast instrument frame and shield cab it can be fatal If the part needs to be checked or repaired the inspection and repair should be carried out after shutting do...

Page 75: ...REAR 115psi 7 9bar 4 0t X5t TIRE PRESSURE FRONT REAR 120psi 8 3bar 125psi 8 6bar 28 CE Label 29 LPG Label Only for LPG truck or dual fuel truck Stick this label on the cylinder Marked Max LPG weight...

Page 76: ...long distance transportation The Fork Lift Truck must be transported by ship train or lorry of over 5T loading Tighten the brake lever place wood blocks to the front and rear wheels and bind the truc...

Page 77: ...LPG single fuel system CPYD15 18 XW21B Y43160X Y48130X CPYD15 18 XW21M XM150 130000 G00 CPQYD15 18 XW21F GK21 Gasoline LPG engine GCT NISSAN XF150 120000 G00 1 5 500 1 75 500 IMPCO LPG dual fuel syst...

Page 78: ...e CPQD20 25 XW22B Y43160X Y48140X CPQD20 25 XW22M RM322 130000 G00 CPYD20 25 XW22F GK25 gasoline engine GCT NISSAN XF250 130000 G00 2 500 2 5 500 IMPCO LPG single fuel system CPYD20 25 XW22B Y43160X Y...

Page 79: ...LC Diesel engine XF250 130000 G00 2 500 2 5 500 CPCD20 25 XW33B Y43160X Y48140X CPCD20 25 XW33M RM322 130000 G00 CPCD20 25 XW43F Cummins QSF2 8T3NA49 Diesel engine XF250 130000 G00 2 500 2 5 500 CPCD2...

Page 80: ...X Y48150X CPQYD30 35 XW22M RM622 130000 G00 CPYD30 35 XW52F GK25 LPG GCT NISSAN XF300 120000 G00 3 500 3 5 500 NIKKI single fuel system CPYD30 35 XW52B Y43160X Y48150X CPYD30 35 XW52M RM622 130000 G00...

Page 81: ...77 Model Engine Hydraulic transmission Rated capacity t Load center mm CPCD30 35 XW56B 4TNV94L BXPHZ Diesel engine Y43160X Y48150X CPCD30 35 XW56M RM622 130000 G00...

Page 82: ...CPCD40 45 XW58B QSF2 8 T4F CUMMINS XB450 130000 G01 4 0 500 4 5 500 CPCD50 55 XXW58B 5 0 500 5 5 500 CPYD40 45 XW57B GM4 3L LX Dual fule engine XB450 130000 G01 4 500 4 5 500 CPYD50 55 XXW57B 5 0 500...

Page 83: ...1 Ground clearance mm 115 115 115 Min outside turning radius mm 1965 1990 2015 Max Grade ability Full load 20 20 20 Wheel base mm 1475 1475 1475 Track F R mm 900 920 900 920 900 920 Service mass kg 25...

Page 84: ...Min outside turning radius mm 1965 1990 2015 Max Grade ability Full load 20 20 20 Wheel base mm 1475 1475 1475 Track F R mm 900 920 900 920 900 920 Service mass kg 2510 2650 2765 Overall dimension L W...

Page 85: ...earance mm 115 115 Min outside turning radius mm 1990 2015 Max Grade ability Full load 20 20 Wheel base mm 1475 1475 Track F R mm 900 920 900 920 Service mass kg 2650 2765 Overall dimension L W H incl...

Page 86: ...nce mm 115 115 Min outside turning radius mm 1990 2015 Max Grade ability Full load 20 20 Wheel base mm 1475 1475 Track F R mm 900 920 900 920 Service mass kg 2650 2765 Overall dimension L W H include...

Page 87: ...ound clearance mm 115 115 Min outside turning radius mm 1990 2015 Max Grade ability Full load 20 20 Wheel base mm 1475 1475 Track F R mm 900 920 900 920 Service mass kg 2650 2765 Overall dimension L W...

Page 88: ...round clearance mm 115 115 Min outside turning radius mm 1990 2015 Max Grade ability Full load 20 20 Wheel base mm 1475 1475 Track F R mm 900 920 900 920 Service mass kg 2650 2765 Overall dimension L...

Page 89: ...3 19 19 19 3 19 19 19 3 19 Ground clearance mm 115 115 115 Min outside turning radius mm 1965 1990 2015 Max Grade ability Full load 20 20 20 Wheel base mm 1475 1475 1475 Track F R mm 900 920 900 920...

Page 90: ...115 130 130 Min outside turning radius mm 2180 2250 2355 2415 Max Grade ability Full load 20 20 15 15 Wheel base mm 1650 1650 1700 1700 Track F R mm 965 973 965 973 1005 975 1005 975 Service mass kg 3...

Page 91: ...d clearance mm 115 115 Min outside turning radius mm 2180 2250 Max Grade ability Full load 20 20 Wheel base mm 1650 1650 Track F R mm 965 973 965 973 Service mass kg 3405 3765 Overall dimension L W H...

Page 92: ...und clearance mm 115 115 Min outside turning radius mm 2180 2250 Max Grade ability Full load 20 20 Wheel base mm 1650 1650 Track F R mm 965 973 965 973 Service mass kg 3405 3765 Overall dimension L W...

Page 93: ...clearance mm 115 115 Min outside turning radius mm 2180 2250 Max Grade ability Full load 20 20 Wheel base mm 1650 1650 Track F R mm 965 973 965 973 Service mass kg 3405 3765 Overall dimension L W H i...

Page 94: ...ound clearance mm 115 115 130 130 Min outside turning radius mm 2180 2250 2340 2415 Max Grade ability Full load 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F R mm 965 973 965 973 1005 975 1005...

Page 95: ...9 18 4 18 3 17 9 18 4 18 3 Ground clearance mm 115 115 130 130 Min outside turning radius mm 2180 2250 2340 2415 Max Grade ability Full load 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F R mm...

Page 96: ...7 9 18 4 18 3 17 9 18 4 18 3 Ground clearance mm 115 115 130 130 Min outside turning radius mm 2180 2250 2340 2415 Max Grade ability Full load 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F R m...

Page 97: ...8 2 Ground clearance mm 115 115 Min outside turning radius mm 2180 2250 Max Grade ability Full load 20 20 Wheel base mm 1650 1650 Track F R mm 965 973 965 973 Service mass kg 3405 3765 Overall dimensi...

Page 98: ...7 17 9 18 4 18 3 17 9 18 4 18 3 Ground clearance mm 115 115 130 130 Min outside turning radius mm 2180 2250 2340 2415 Max Grade ability Full load 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F...

Page 99: ...15 115 130 130 Min outside turning radius mm 2180 2250 2340 2415 Max Grade ability Full load 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F R mm 965 973 965 973 1005 975 1005 975 Service mass k...

Page 100: ...ning radius mm 2180 2250 2340 2415 Max negotiable gradient laden 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F R mm 965 973 965 973 1005 975 1005 975 Service mass kg mechanis m hydraulic 3405...

Page 101: ...m h 19 4 19 4 18 6 17 9 Ground clearance mm 115 115 Min outside turning radius mm 2180 2250 Max Grade ability Full load 20 20 Wheel base mm 1650 1650 Track F R mm 965 973 965 973 Service mass kg 3405...

Page 102: ...115 115 130 130 Min outside turning radius mm 2180 2250 2340 2415 Max Grade ability Full load 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F R mm 965 973 965 973 1005 975 1005 975 Service mass...

Page 103: ...Min outside turning radius mm 2180 2250 2340 2415 Max Grade ability Full load 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F R mm 965 973 965 973 1005 975 1005 975 Service mass kg 3405 3765 43...

Page 104: ...Min outside turning radius mm 2180 2250 2340 2415 Max Grade ability Full load 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F R mm 965 973 965 973 1005 975 1005 975 Service mass kg 3405 3765 43...

Page 105: ...tside turning radius mm 2180 2250 2340 2415 Max Grade ability Full load 20 20 20 20 Wheel base mm 1650 1650 1700 1700 Track F R mm 965 973 965 973 1005 975 1005 975 Service mass kg 3405 3765 4350 4705...

Page 106: ...utside turning radius mm 2690 2720 2875 2905 Max Grade ability Full load 20 20 20 20 Wheel base mm 2000 2000 2150 2150 Track F R mm 1173 1130 1203 1130 1203 1130 1203 1130 Service mass kg 6500 6700 68...

Page 107: ...outside turning radius mm 2690 2720 2875 2905 Max Grade ability Full load 20 20 20 20 Wheel base mm 2000 2000 2150 2150 Track F R mm 1173 1130 1203 1130 1203 1130 1203 1130 Service mass kg 6500 6700 6...

Page 108: ...tside turning radius mm 2690 2720 2875 2875 Max Grade ability Full load 20 20 20 20 Wheel base mm 2000 2000 2150 2150 Track F R mm 1173 1130 1203 1130 1203 1130 1203 1130 Service mass kg 6500 6700 685...

Page 109: ...outside turning radius mm 2690 2720 2875 2875 Max Grade ability Full load 20 20 20 20 Wheel base mm 2000 2000 2150 2150 Track F R mm 1173 1130 1203 1130 1203 1130 1203 1130 Service mass kg 6500 6700...

Page 110: ...0 Min outside turning radius mm 2690 2720 2875 2905 Max Grade ability Full load 20 20 20 20 Wheel base mm 2000 2000 2150 2150 Track F R mm 1173 1130 1203 1130 1203 1130 1203 1130 Service mass kg 6500...

Page 111: ...ide turning radius mm 2690 2720 2875 2875 Max Grade ability Full load 20 20 20 20 Wheel base mm 2000 2000 2150 2150 Track F R mm 1173 1130 1203 1130 1203 1130 1203 1130 Service mass kg 6500 6700 6850...

Page 112: ...side turning radius mm 2690 2720 2875 2875 Max Grade ability Full load 20 20 20 20 Wheel base mm 2000 2000 2150 2150 Track F R mm 1173 1130 1203 1130 1203 1130 1203 1130 Service mass kg 6500 6700 6850...

Page 113: ...ose door make sure left and right door close before working 3 The glass of left and right door can be moved by draw button on the glass 4 The rear door can be opened by loosing lock buckle Disassemble...

Page 114: ...rument frame 1 Instrument frame discreteness 2 left protect cover 3 bolt discreteness 5pcs 4 rear protect cover 5 bolt discreteness 6 bracket 7 right protect cover 8 bolt discreteness M5 16 3pcs 9 fro...

Page 115: ...emove 2 bolts inside left rear legs hand spanner 9 Remove the assistant water tank of right leg and 2 pcs tighten bolt 10 Remove the glass on cabin caution dismantle backboard and beam 11 Sling the ca...

Page 116: ...d 1 rearview mirror 2 cabane 3 clearstory board 4 cover board 5 bolt M5 12 6 right support assembly 7 glue pipe 8 pipe hoop 9 gasket 14 8 pcs 10 gasket 14 8 pcs 11 bolt M14 12 left support 13 bolt M16...

Page 117: ...ment frame 3 Dismantle the pedal mat rear soleplate front soleplate see the overhead part 4 Remove switch connection of fan rain wiper alarm light etc 5 Remove 4 bolts inside left front and right fron...

Page 118: ...at this time and then screw off the dust cover on the inflation valve insert inflation plug open the inlet limit valve to fuel When the LPG fuel to 80 of the cylinder volume take out the inflation plu...

Page 119: ...east every two weeks to avoid gasoline deterioration 3 After engine starts do not change fuel at once and the engine should be in normal work temperature before change fuel When using LPG you should p...

Page 120: ...the container is full c Level indication The gauge on the tank shows remaining volume d Outpouring limit valve When outpouring exceeds the stated value or the pipe is broken the outpouring device on t...

Page 121: ...and ring finger to pull lock buckle out 2 Keep holding lock buckle up and push up tightening device until it touches cylinder 3 Keep the lock buckle out and pull downward the whole tightening device 4...

Page 122: ...Requirement to Truck used LPG Item Quality index Test method 1 2 3 Vapour pressure 37 8 gage pressure kPa 1430 890 1430 660 1340 GB T 6602 a Mass fraction of component Dimethylmethane 85 65 85 40 65...

Page 123: ...9 2003 9 Procedure for replacing LPG cylinder 1 Wear canvas gloves to avoid leaking gas from preventing frostbite to fingers while changing gas 2 Make sure the place is clear and well ventilated when...

Page 124: ...connect the connecting pipe with quick connector open outlet shutoff valve 8 smear every joint with soap bubble to check whether the joint is leaking if there is leaking at joint eliminate the proble...

Page 125: ...shutoff valve make sure there are no leaks and convenient to use 3 It must check the cylinder assembly whether leak or not per charging and fixing it on truck 4 Prevent dust from entering into the in...

Page 126: ...ify cylinder mark and color sign 20 Cylinder must be taken to the special unit per 5 years to inspect the unit have qualification awarded by pressure vessel safety supervisor bureau 21 Observe the lev...

Page 127: ...123 pipes IMPCO single fuel system 120...

Page 128: ...124 LPG system drawing...

Page 129: ...r with paper board so as not to damage battery poles Battery must be handled with care Tilt inversion throw or heavy load is prohibitted in case of battery leakage or damage As to the battery equips w...

Page 130: ...nnect negative earth wire to avoid discharging by additional current release 3 Keep the battery charged completely when the battery cannot be removed from the truck 4 Make a general schedule charge ev...

Page 131: ...th wire to avoid discharging by additional current release 3 Keep the battery charged completely when the battery cannot be removed from the truck 4 Make a general schedule charge every 30 45 days if...

Page 132: ...d negative to avoid damage of electric equipment or battery Never cover electric things on the battery to avoid battery short cut To avoid electrolyte contact eyes skin or clothes Never let the childr...

Page 133: ...and the mast is inclined back 5 The weight of cargo shouldn t exceed the combined limit of the carrying capacity of forklift and attachment It is not allowed to have a partial load at high position It...

Page 134: ...3 Check assembly of attachment to ensure no movement on carriage 4 After hang attachment embed the rise catch block to the gap of top beam Ensure the center line of the attachment offset from the cen...

Page 135: ...brake pedal before starting in case of slipping 2 Forward or Reverse Protection After the engine has started shift the gear switch to first gear of forward or reverse the vehicle is able to start If...

Page 136: ...if the sequence is not followed the truck will not start Before unlocking the working device put the tilting lever and the attachment lever back to the original position Abnormity of OPS Controller I...

Page 137: ...N12053 2001 and meets with 2000 14 EC 2005 88 EC Vibration parameter is measured according to ISO5349 2 2001 EN13059 2002 Model Vibration coefficient m s 2 At the operator position measure with sound...

Page 138: ...1 02 89 103 8 CPYD45 XW68 1 15 89 103 8 CPYD50 XXW68 1 17 88 103 7 CPYD55 XXW68 1 16 88 103 7 Electromagnetism compatibility is measured according to EN12895 2000 and meet with 2004 108 EE Directive S...

Page 139: ...FOLLOWING EUROPEAN DIRECTIVES 2006 42 EC MACHINERY DIRECTIVE 2004 108 EC EMC DIRECTIVE 2000 14 EC 2005 88 EC NOISE EMISSION DIRECTIVE EQUIPMENT ACCORDING TO THE DEFINITION GIVEN BY ANNEX I ITEM 36 OF...

Page 140: ...l ren hiermit dass die Maschine product name Internal combustion counterbalanced Forklift Truck Produktbezeichnung commercial name Handelsbezeichnung function Funktion model CPCD40 45 XW35 CPCD50 55 X...

Page 141: ...137 XVI Maintenance record Date Item of maintenance Signature Remark...

Page 142: ...NGCHA GROUP CO LTD Address For OVERSEAS USERS Address 666 Xiangfu Road Hangzhou Zhejiang China Fax 0086 571 88926789 0086 571 88132890 ZIP 311305 Web http www hcforklift com E mail sales hcforklift co...